Molded plastic container

ABSTRACT

A one-piece molded plastic container as a carrying case or carton for bottles and the like having a collapsible construction which permits the container to be readily collapsed into a number of forms for shipment, storage, cleaning and reuse.

United States Patent Inventors Appl. No.

Filed Patented Assignee Robert Culver Rossburg;

Charles W. Ridge, Middletown, both of, Ohio Apr. 17, 1969 June 29, 1971Culver Industries, Inc.

Ansenia, Ohio MOLDED PLASTIC CONTAINER 10 Claims, 13 Drawing Figs.

U.S.Cl 220/111, 220/102, 229/52 lnt.Cl 865d 5/46,

[50] Field of Search 220/1 11, 102, 1 12, I13, 1 14, l 15; 229/52 B, 28

[56] References Cited UNITED STATES PATENTS 2,525,686 10/1950 Kowal220/111 3,178,052 4/1965 Bromley 220/102 3,359,873 12/1967 Carle et a1.220/102 X Primary ExaminerDavid M. Bockenek Attorney-Wood, Herron &Evans ABSTRACT: A one-piece molded plastic container as a carrying caseor carton for bottles and the like having a collapsible constructionwhich permits the container to be readily collapsed into a number offorms for shipment, storage, cleaning and reuse.

PATENTEU JUN29 IQYI sum 2 BF 3 PATENIEfiJuwzslen 3 389 553 SHEET 3 OF 3INVENTORS.

MOLDED PLASTIC CONTAINER BACKGROUND OF THE INVENTION Molded rigidplastic cartons or bottle carriers are known as disclosed, for example,in U.S. Pat. No. 3,283,947 and No. 3,045,862. These types of rigidcarriers however have one major disadvantage in that they are notcollapsible. Consequently, in storage and shipment by the manufacturer,they present the undesirable feature of wasted space. This undesirablefeature has also prevented complete acceptance of rigid plasticcartons-by retailers and consumers. Moreover, while most known rigidplastic cartons are somewhat durable, they are not easily cleanedprimarily because the rigid compartments have comers and surfaces whichare normally inaccessable to cleaning brushes. In addition, asillustrated by these patents, the most common types of rigid plasticcarrying cases comprise two separately molded parts, a basket portionand an attachable handle. These multicomponent parts usually rely uponsnapping tabs to hold them together, with the tabs bearing the load ofthe basket, and it is not uncommon under use conditions for these tabsto loosen or fail.

Collapsible plastic cartons have been proposed. In general, they haveone or more deficiencies. The usual collapsible plastic cartons are notone-piece and they possess the same disadvantages as the multicomponentrigid cartons just mentioned. Cleaning problems still attend knownso-called collapsible or semicollapsible structures because they do notcollapse to a form which can easily be thoroughly cleaned. Those cartonstructures which tend to be more completely collapsible usually lackstrength or the number and location of hinges, particularly at criticalloading areas, reduce the life of the carton.

Thus, heretofore, in brief, there have been no satisfactory proposalsfor a one-piece molded plastic carton or carrying case having theadvantages of a complete rigid unit which is adapted to collapse forshipment, storage, cleaning or reuse. Moreover, heretofore, there hasbeen no satisfactory onepiece plastic carton or carrier which has thecapability of collapsing into a number of structural forms to facilitatevarious modes of shipment, storage and reuse depending upon spacerequirements or other factors. There is a need for such a carton whichembodies these characteristics, and yet is of simple but soundconstruction thereby affording ease of manufacture and extended usagewithout failure. like.

SUMMARY OF THE INVENTION This invention is directed to a new concept inone-piece molded collapsible plastic containers made from rigid, durableplastic material. This invention also provides a unique onepiece plasticcontainer structure which is collapsible into a number of structuralforms for ready storage and/or transportation in a manner heretoforeunachieved by other plastic cartons of the rigid type. Moreover, theplastic container according to this invention is collapsible into astructural form which permits complete exposure of all its surface areasfor cleaning in a manner heretofore unobtainable by known rigid plasticcartons. Even with its highly advantageous features of structuralflexibility, the container structure is durable and ex ceedingly safefor use in containing or carrying articles such as glass pop bottles andthe like.

One form of the invention is a one-piece molded plastic carrying casefor bottles comprising a generally rectangular bottom wall and a pair oftubularlike members in adjacent relationship each having a generallyrectangular open-ended receiving compartment. Each rectangularcompartment has a sidewall, a pair of end walls and a central wallhaving an integral handle portion. The compartment walls are integrallyconnected at the opposite side margins by four vertical flexible hinges.The central and end walls of each compartment have free top and bottommargins to permit collapse along the vertical hinges. Each of thesidewalls is integrally connected at its bottom margin to oppositemargins of the bottom wall by a marginal flexible horizontal hinge. Inthe carrying case use position, the central walls are in face-to-facerelation with one another to provide the tubularlike members in adjacentrelationship. This structure is collapsible from its use position alongthe vertical hinges of the compartment walls and the marginal horizontalhinges of the bottom wall'into a substantially flattened form.

In a preferred form, the central panels of each of said compartmentshave integrally molded cooperating means for selectively locking thecentral panels in face-to-face relation with one another. This lockedstructural position is sometimes referred to herein as the use or bottlecarrying position where the container is in the shape of a generallyrectangular two, four, six or eight-pack configuration. In theeight-pack configuration, the carrying case for bottles, the tubularlikemembers are divided by three integrally molded vertical crosspanels. Thecross-panels are integrally hinged along vertical lines between thecentral wall and sidewall of each tubularlike member and spaced apartfrom the end walls to form individual compartments for the articlecarried.

In another of its aspects, a preferred carrying case structure furthercomprises a rectangular bottom wall having a flexible medial integralhinge extending the full length of the bottom wall between oppositemargins thereof. When this feature is incorporated into the structurejust discussed, and the central panels are locked in face-to-facerelation with one another, the medial hinge of the bottom wall permitscollapse of the carrying case. Alternatively, as above discussed, thecentral walls can be unlocked and separated from their face-to-facerelation and the container may be collapsed by folding along theflexible vertical and horizontal hinges. Thus, when the bottom panel isprovided with an integral medial hinge, the container structure can becollapsed into multiple collapsed positions.

One-piece molded collapsible plastic carrying cases embodying thestructure above discussed, wherein the locking means locks the centralpanels, provides structural stability. In this form, the bottom wall hasproved adequate support for carrying or containing the articles disposedin the open-ended compartments without further support being given tothe bottom wall. However, in another aspect of this invention,integrally molded means are provided for selectively locking the endwalls of each compartment at their bottom margins to the bottom wall.This has the additional advantage of maintaining the overall rectangularconfiguration of the carrying case and,

in addition, provides further support for the load-bearing bot-.

tom wall of the container, overall structural stability and balance. 7

Thus, by reason of its unique structure, the container of this inventioncan be opened and its tubularlike compartment members can easily becleaned due to their readily accessible interior surface structure.Unlike known rigid cartons, there are no basket corners and relativelyinaccessible surfaces which are difficult to clean. Moreover, the cartoncan be collapsed from a use or carrying position without having todisengage its central walls whereby its storage is facilitated in adiffercnt form covering less surface area. Stacking problems heretoforeassociated with rigid cartons are thus eliminated or substantiallyreduced with the unique collapsing features of this inventive structure.The carton can be fabricated of rigid plastic material which isextremely durable and by reason of the unique construction can bemaintained in a clean state without special cleaning equipment.

Other disadvantages and embodiments of this invention will becomeapparent in view of the following description with reference to thedrawings in which:

FIG. l is a perspective view of a one-piece collapsible plastic carryingcase of this invention its normal use position on a reduced scale;

FIG. 2 is an exploded partial view of a vertical hinge connectionbetween a cross-panel and a sidewall of FIG. 1;

FIG. 3 is top view of FIG. 2 showing the flexibility of the moldedhinge;

FIG. 4 is an exploded partial cross-sectional view taken along the line4-4 of FIG. 1 and demonstrates a locking means for removably connectingthe bottom wall with the end walls at their margins;

FIG. 5 is a plan view of the carton shown in FIG. 1 in an open positionillustrating the interior thereof on a smaller scale;

FIG. 6 is a plan view of the carton shown in FIG. 5 in a collapsedposition;

FIGS. 7 and 8 are end and side views, respectively, of the carton shownin FIG. 1 on a reduced scale, collapsed from its normal use position;

FIG. 9 is an enlarged cross-sectional view taken along line 9-9 of FIG.7 showing a snap button locking means for the central wall handleportion;

FIG. 10 is a top view of FIG. 1',

FIG. 11 is a top view of FIG. 1, showing the carton partially collapsed;

FIG. 12 is a side view of FIG. 5;

FIG. 13 is an enlarged cross-sectional view taken along line 13-13 ofFIG. 12..

The invention is herein illustrated as embodied in a molded plasticcarrying case of FIG. 1 that is adapted to receive eight bottles in twoparallel rows of four bottles each. The onepiece plastic carrying case20 of FIG. 1 comprises a generally rectangular bottom wall 21 and a pairof tubularlike member, generally at 23, 23, in adjacent relationshipduring normal use in the bottle carrying position of FIG. 1. Thestructural relationship of bottom wall 21 and tubularlike members 23, 23is shown best in FIGS. 5, 12 and 13.

The bottom wall 21 has an integral flexible medial hinge 22 extendingsubstantially parallel to opposite margins of wall 21 and over its fulllength. Each tubularlike member 23 has a generally rectangularopen-ended receiving compartment 23A as envisioned with particularreference to the outer periphery of the cross-sectional view of FIG. 13.Compartment 23A comprises a sidewall 26, a pair of end walls 27,27 and acentral wall 28 having an integral handle 29. Handle 29 comprisescooperating hand-bearing openings formed in the central walls 28. Thecompartment walls 26, 27, 28 are integrally connected at their oppositeside-margins by four vertical flexible hinges 32. The central wall 28and end walls 27 have free top and bottom margins as indicated generallyat 34 and 35, respectively, in FIGS. 6 and 12. These free margins 34, 35are essential, along with flexible vertical hinges 32, to permitcollapse of compartments 23A and carrying case 20. Each sidewall 26 isintegrally connected at its bottom margin to opposite margins of bottomwall 21 by a marginal flexible horizontal hinge 36. The central walls 28of each compartment 23A are in face-to-face relation with one another asshown in FIG. 1 in the normal use or bottle carrying position. Withreference to FIGS. 6 and 12, it is understood that hinges 32 and 36permit collapse of carrying case 20.

In the illustrated carrying case 20, an eight-pack" structuralarrangement is provided wherein the compartments 23A are divided byvertical cross-panels 37 which are integrally connected between eachcentral wall 28 and corresponding sidewall 26 at opposite side marginsof panels 37 by vertical flexible hinges 38. The cross-panels 37 areevenly spaced apart from end walls 27, to form individual compartmentsfor the articles carried, and have free top and bottom margins like endwalls 27 (this is not shown but is appreciated with reference to FIGS. 6and 12).

Referring to the bottle carrying position of FIG. 1, the integralcentral walls 28 of the carrier 20 are locked in face-toface relation byintegrally molded cooperating lock means or two button snaps showngenerally at 41 having a mushroom button 42 and cooperating cone-shapedhole 43. Button snap 41 is shown in cross section more particularly inFIG. 9. Also in bottom wall 21 are integrally molded end lugs 45 forselective locking engagement with the slits 46 in the end wall 27 ofcompartments 23A. This is shown in FIG. 4. It will be appreciated thatthe snapping buttons 42 lock the hinged pair of tubularlike members 23together to form the eight-pack and the bottom wall lugs 45 engage theslits 46 of the end walls 27 of the pairs of tubular members 23 toselectively lock the bottom wall 21 to the sidewalls 26. These lockingmeans provide for overall carton stability and balance. It is to beemphasized, however, that these locking means are presently preferredembodiments of this invention, but it is envisioned that such means,particularly the bottom wall locking means, may be eliminated and stillprovide a useful structure. In the event of eliminating both lockingmeans, the case 20 is held by hand in the carrying position byhand-bearing openings formed in central walls 28 and articles carried intubularlike members 23 fill out the eight-pack configuration.

The carrying case 20 is collapsed from its locked or use position andflattened into a form represented by the end and side views of FIGS. 7and 8, respectively for storage, transportation or reuse. With referenceto FIG. 11, compartments 23A can be readily collapsed by applyingpressure to the end walls 27 of case 20 thereby automaticallydisengaging the bottom wall lugs 45 from walls 27 and thereaftercollapsing walls 27 along the flexible hinges 32 and 38 toward theirrespective center walls 28 while the bottom wall 21 folds outwardlyalong its medial hinge 22.

The case 20 can also be collapsed into another form for cleaning asshown in FIGS. 5 and 12 and, then further completely flattened as shownin FIG. 6. When this type collapse is desired, the central walls 28 areseparated causing the button snaps 41 and lugs 45 to disengage. Thecompartments 23A pivot on hinges 36 into a substantially horizontalposition shown in plan view of FIG. 5. The tubular members 23 can easilybe cleaned in this position. Also, in this open position, the tubularmembers 23 can be collapsed by folding the sidewalls 26 and centralwalls 28 towards one another along the integral hinges 32 in oppositedirections to flatten the case 20 into an extended open position asillustrated in FIG. 6.

The container of this invention is constructed of durable plasticmaterial preferably of the thermoplastic type such as polyethylene orpolypropylene which can be formed by molding techniques such asinjection molding techniques. The thicknesses of such materials whichprovide rigidity and durability to the walls and panels of thecontainers are usually on the order of about 0.0056 inch forpolypropylene for example. The integral hinges are reduced in thicknessand, for the mentioned wall thicknesses of polypropylene, can be in therange of about 0.0012-21 inch or about one-fifth the thickness of thewalls. As shown in FIGS. 2 and 3, the hinges can be provided by reducingthe thickness of plastic in a tapering, arcuate manner to give strengthto the flexible hinge. Of course, thicknesses to provide the desiredwall rigidity, strength and hinge flexibility can vary over a wide rangedepending upon materials used.

Certain other features of a preferred container of the invention havebeen illustrated in the drawings. The diagonal openings 48 in thecentral walls 28 are provided to save material and to embody protectivecross-straps 49 to avoid contact of the articles carried with oneanother such as glass bottles, thereby avoiding breakage. Voids 50spaced along the horizontal hinges 36 primarily function as aids infolding the walls along hinges 36.

Thus, the container illustrated in the drawings demonstrates the uniquemulticollapsible structure of a preferred form of a bottle carrying casein accordance with the principles of this invention. The container canbe conveniently collapsed from its use position, as shown in FIG. 1,without having to unlock its walls, thereby storage is facilitated in aform covering a minimum amount of surface area and cross-sectional area.This permits easy storage either in the sonsumers closet or as mentionedin the retailers storage room or racks, without wasting space. Moreover,by reason of the containers multicollapsibility, it can be opened byunsnapping the locking elements and in this position can be thoroughlycleansed. It will be appreciated that in the opened extended position ofthe carton, as illustrated in FIG. 5, that all the surfaces of thestructure, including the interior surfaces of the hollow tubularmembers, are exposed for cleaning. Accordingly, unlike known rigidcanons, there are no basket comers or relatively inaccessible surfaceswhich are difficult to clean. in addition, the carton can be stored andshipped in this extended open position by collapsing the tubular membersin the manner illustrated and discussed above with reference to FIG. 6.

It is to be understood that there are other modifications which willbecome apparent to those having ordinary skill in the art in view of theabove disclosure and these are within the spirit and scope of thisinvention.

What I claim is:

1. In a one-piece molded collapsible plastic container, the combinationcomprising,

a generally rectangular bottom wall, and

a pair of tubularlike members in adjacent relationship each having agenerally rectangular open-ended receiving compartment comprising asidewall, a pair of end walls and a central wall, said compartment wallsbeing integrally connected at their opposite side-margins by fourvertical flexible hinges, each said sidewall being integrally connectedat its bottom margin to opposite margins of said bottom wall by amarginal flexible horizontal hinge, said central walls in face-to-facerelation with the other central wall, said vertical flexible hinges andsaid flexible horizontal hinges permitting collapse of the container.

2. The container of claim 1 further comprising integrally molded meansfor selectively locking said central walls in face-to-face relation.

3. The container of claim 2 further comprising said bottom wall having aflexible medial integral hinge extending substantially parallel to saidmarginal horizontal hinges over the full length of said bottom wall,said medial hinge permitting collapse of the carton when said centralwall members are locked in face-to-face relation.

4. The container of claim 1 further comprising said central walls havingintegrally molded cooperating means for forming a handle.

5. The container of claim 4 wherein said means comprise cooperatinghand-bearing openings formed in said central walls.

6. The container of claim 3 further comprising integrally molded meansfor selectively locking said end walls at their bottom margins to saidbottom wall.

7. A one-piece molded collapsible plastic carrying case for bottles andthe like comprising,

a generally rectangular bottom wall having a flexible medial integralhinge extending the full length of said bottom wall between oppositemargins of said bottom wall,

a pair of tubularlike members in adjacent relationship each having agenerally rectangular open-ended receiving compartment comprising asidewall, a pair of end walls and a central wall, said compartment wallsbeing integrally connected at their opposite side-margins by fourvertical flexible hinges, said central and end walls having free top andbottom margins, each said sidewall being integrally connected at itsbottom margin to said opposite bottom wall margins by a marginalhorizontal hinge, said central walls in face-to-face relation with oneanother,

integrally molded cooperating means in each of said central walls forforming a handle, and

integrally molded means for selectively locking said central walls inface-to-face relation, said hinges permitting collapse of the carryingcase.

8. The plastic carrying case of claim 7 further comprising integrallymolded means for selectively locking said end walls at their bottommargins to said bottom wall to prevent, when desired, said hinges frompermitting collapse of the carrying case.

9. The plastic carrying case of claim 7, said compartment furthercomprises at least one cross-panel integrally connected between saidside and central walls at opposite-side margins of said panel byvertical flexible hinges, said crosspanel evenly spaced apart from saidside walls and having free partment further comprises threecross-panels.

1. In a one-piece molded collapsible plastic container, the combinationcomprising, a generally rectangular bottom wall, and a pair oftubularlike members in adjacent relationship each having a generallyrectangular open-ended receiving compartment comprising a sidewall, apair of end walls and a central wall, said compartment walls beingintegrally connected at their opposite side-margins by four verticalflexible hinges, each said sidewall being integrally connected at itsbottom margin to opposite margins of said bottom wall by a marginalflexible horizontal hinge, said central walls in face-to-face relationwith the other central wall, said vertical flexible hinges and saidflexible horizontal hinges permitting collapse of the container.
 2. Thecontainer of claim 1 further comprising integrally molded means forselectively locking said central walls in face-to-face relation.
 3. Thecontainer of claim 2 further comprising said bottom wall having aflexible medial integral hinge extending substantially parallel to saidmarginal horizontal hinges over the full length of said bottom wall,said medial hinge permitting collapse of the carton when said centralwall members are locked in face-to-face relation.
 4. The container ofclaim 1 further comprising said central walls having integrally moldedcooperating means for forming a handle.
 5. The container of claim 4wherein said means comprise cooperating hand-bearing openings formed insaid central walls.
 6. The container of claim 3 further comprisingintegrally molded means for selectively locking said end walls at theirbottom margins to said bottom wall.
 7. A one-piece molded collapsibleplastic carrying case for bottles and the like comprising, a generallyrectangular bottom wall having a flexible medial integral hingeextending the full length Of said bottom wall between opposite marginsof said bottom wall, a pair of tubularlike members in adjacentrelationship each having a generally rectangular open-ended receivingcompartment comprising a sidewall, a pair of end walls and a centralwall, said compartment walls being integrally connected at theiropposite side-margins by four vertical flexible hinges, said central andend walls having free top and bottom margins, each said sidewall beingintegrally connected at its bottom margin to said opposite bottom wallmargins by a marginal horizontal hinge, said central walls inface-to-face relation with one another, integrally molded cooperatingmeans in each of said central walls for forming a handle, and integrallymolded means for selectively locking said central walls in face-to-facerelation, said hinges permitting collapse of the carrying case.
 8. Theplastic carrying case of claim 7 further comprising integrally moldedmeans for selectively locking said end walls at their bottom margins tosaid bottom wall to prevent, when desired, said hinges from permittingcollapse of the carrying case.
 9. The plastic carrying case of claim 7,said compartment further comprises at least one cross-panel integrallyconnected between said side and central walls at opposite-side marginsof said panel by vertical flexible hinges, said cross-panel evenlyspaced apart from said side walls and having free top and bottommargins.
 10. The plastic carrying case of claim 9 wherein saidcompartment further comprises three cross-panels.